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Woodward 505 Product Manual

Digital control for steam turbines
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Product Manual 26839V2
(Revision NEW, 2/2015)
Original Instructions
505 Digital Control
for Steam Turbines
8200-1300, 8200-1301, 8200-1302
Manual 26839 consists of 2 volumes (26839V1 & 26839V2).
Volume 2

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  • Page 1 Product Manual 26839V2 (Revision NEW, 2/2015) Original Instructions 505 Digital Control for Steam Turbines 8200-1300, 8200-1301, 8200-1302 Manual 26839 consists of 2 volumes (26839V1 & 26839V2). Volume 2...
  • Page 2 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Servo Position Controller (SPC) ................13   Real Power Sensor ....................15   Engine Generator Control Package/Load Sharing (EGCP-3 LS)......16   Applying the 505 with Redundant I/H or I/P Converters ........19 3. A ............. 21  HAPTER PPLICATION OTES  ...
  • Page 4 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Contents C. P ........... 102  PPENDIX ASSWORD NFORMATION   General .......................102   Monitor User Level....................102   Operator User Level Password ................102   Service User Level Password ................102   Configure User Level Password .................102  ...
  • Page 5 Figure D-3. SOS Server status dialog box ............104   Figure D-4. SOS – New Session box ..............105   Figure D-5. SOS - Enter 505 TCP/IP address ............ 105   Figure D-6. SOS – Active Links dialog box ............105  ...
  • Page 6 Configuration Window ..............133   Figure I-1. HW Simulation Mode Access ............134   Table 2-1. CAN Wiring from 505 to VS-II ............. 12   Table 3-1. Example Application Summary ............23   Table 4-1 Mode Access by User Level ..............49...

  • Page 7: Warnings And Notices

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Warnings and Notices Important Definitions This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 8: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. To prevent damage to electronic components caused by improper handling, read and observe the precautions in Woodward manual 82715 , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules.

  • Page 9: Introduction

    Woodward products and example configurations of typical steam turbine applications. This volume gives users an idea of the 505 Control’s capabilities, and how to apply them to a system. Typical applications are schematically shown and their functionality explained. Programming and Start/Run mode notes are given for each application to assist application programmers in configuring the 505 for their application.

  • Page 10: Chapter 1. Service Tools

    Instructions for installing and using these tools are found in the Appendices of this volume of the manual. All service tool interfaces to the 505 are Ethernet connections and can be used on any of the 4 Ethernet ports. The only requirement is that the PC connecting to the control has an IP address on the same domain (as with any typical network).

  • Page 11: Chapter 2. Peripheral Devices

    Some of these devices are able to be connected to the 505 by a digital communication link (either Ethernet or CAN depending on the product). Through this link the 505 display will allow the user to monitor many signals and status LED’s from this external device.

  • Page 12: Figure 2-2. Configuration/Woodward Links/Dslc-2

    This is a “Woodward Link” device. Figure 2-2. Configuration/Woodward Links/DSLC-2 To enable the Woodward Link feature select the check box on the screen above and enter the slave address and the IP address of the DSLC-2 device. The figure above shows the factory default IP addresses of the DSLC-2 and Ethernet port 3 of the 505.

  • Page 13: Varistroke Ii (Electro-Hydraulic Actuator)

    The VariStroke-II is a linear electro-hydraulic actuator that is designed to provide the linear actuation force to operate steam turbine control valves or valve racks. This actuator can be directly networked with the 505 controller to reduce system complexity and wiring requirements.

  • Page 14: Figure 2-6. Configuration/Woodward Links/Vs-Ii

    Manual 26839V2 Figure 2-6. Configuration/Woodward Links/VS-II To enable the Woodward Link feature select the check boxes on the screen above to enable the CAN1 Link and confirm usage of the VariStroke II actuator, then enter the Device ID. If an analog (4-20 mA) demand signal is going to be connected to the VariStroke in addition to the CAN link, then select the desired function for this signal (AI Backup is recommended).

  • Page 15: Mfr300 (Multi-Function Relay)

    The LS-5 series protection relays integrate generator breaker synchronization, power sense and protection functions all into one package. This device is designed to function in combination with a prime mover controller like the 505 to allow accurate generator control as well as provide required generator protection.

  • Page 16: Figure 2-10. Servo Position Controller

    SPC can interface. Below is one example of how the 505 and SPC can be used on Integrating Servo Valves. The SPC can also handle many variations of feedback devices.

  • Page 17: Real Power Sensor

    Woodward Real Power Sensors have terminals labeled “Output” and terminals labeled “KW Readout”. The “KW Readout” terminals provide a 4–20 mA signal proportional to real power which is used by and compatible with the 505 control. Thus the RPS terminals labeled “Output” are designed and typically compatible only to Woodward’s 2301 type of control.

  • Page 18: Engine Generator Control Package/Load Sharing (Egcp-3 Ls)

    These ports can be configured to use Woodward Watch Window software, an external HMI and Modbus communication, or Servlink DDE software. The 505 can be programmed to use the EGCP-3 LS as a synchronizer only, or as a synchronizer and load control. The EGCP-3 LS provides either phase match or slip frequency synchronizing, and ties into the unit automatic voltage regulator to match voltages before paralleling.

  • Page 19: Figure 2-13. Egcp-3 Control

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Once the generator is synchronized the EGCP-3 LS soft-loads the unit to the load setting determined by the mode of operation (base load, load sharing, Process control). When commanded the EGCP-3 LS can also soft-unload the unit and issue a breaker-open command at a set power level.

  • Page 20: Figure 2-15. Egcp-3 Ls Interface Wiring

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2   Figure 2-15. EGCP-3 LS Interface Wiring The following Bus Protections are available with the EGCP-3 LS:  Over/Under Voltage (59, 27)  Over/Under Frequency (81O, 81U)  Directional (Forward/Reverse) Power (32) * ...

  • Page 21: Applying The 505 With Redundant I/H Or I/P Converters

    Woodward manuals 26122 and 26194. Applying the 505 with Redundant I/H or I/P Converters The 505 can be applied in simplex or redundant actuator systems. For redundant actuator applications Actuator Channel 1 is configured for HP Demand and Channel 2 is configured for HP2 Demand with zero offset. This will supply both...

  • Page 22: Figure 2-17. Typical Redundant I/P System With A Pressure Selecting Relay Valve

    Functionality Details Utilizing a two-actuator output configuration provides redundancy all the way to the actuator level. The typical redundant I/H (or I/P) system will convert the 505 actuator milliamp output into a corresponding hydraulic (or pneumatic) pressure positioning the servo-cylinder. Both converters are supplying the appropriate pressure to position the steam valves to the demand requested by the control.

  • Page 23: Chapter 3. Application Notes

    A combination of the Speed PID and its setpoint limits allow this PID to limit unit load. When used as a unit load limiter, it is recommended that the 505 be configured to sense and control only true generator load. If applying the 505 system to a soft grid (utility frequency varies greatly) it is recommended that unit load limiting be performed by the Auxiliary PID not the Speed PID.

  • Page 24: Example Applications

    Modbus communications. With this configuration when the Aux PID is enabled the Speed PID is disabled and tracks the Auxiliary PID’s output. To control or limit any of the listed parameters, the 505 must be programmed to accept an Auxiliary analog input signal representing that parameter’s level. The...
  • Page 25 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Example–To configure the 505 to perform a Turbine Exhaust pressure limiting function use Example 1, the “Pump or Compressor Discharge Pressure Control with Turbine Inlet Pressure Limiting” application for reference. With this example substitute exhaust pressure for inlet pressure and disregard any program settings specified to control pump or compressor discharge pressure.

  • Page 26: Figure 3-1. Pump Or Compressor Discharge Pressure Control With Turbine Inlet Pressure Limiting

    Figure 3-1 and described below. With this application pump/compressor discharge pressure control is performed within the 505 through the Cascade controller. Because the discharge pressure being controlled, typically affects many other plant processes, a plant Distributed Control System (DCS) may be used to monitor plant process conditions and set the Cascade setpoint position.
  • Page 27 Modbus commands, or the 505 service panel. The following list of notes is provided as a reference for application programmers to follow when configuring the 505 to achieve any of the control and limiting actions shown in Figure 3-1: 505 Configuration Notes for Example 1 Operating Param: This is not a Generator application.
  • Page 28 In this example the turbine can be tripped by several devices, one of these devices is the 505 control. To provide feedback to the 505 control that the turbine is tripped, a contact from the trip string is wired into the External Emergency Shutdown input (TB12).

  • Page 29: Figure 3-2. Inlet Pressure Control With Automatic Synchronizing & Generator Power Limiting

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Example 2–Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Figure 3-2. Inlet Pressure Control with Automatic Synchronizing & Generator Power Limiting Woodward...
  • Page 30 With this application turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator.
  • Page 31 Because a two wire, loop powered transducer is used to interface with this signal, the 505 back cover was removed and JPR8 installed. The 505 was configured to accept a contact from a panel mounted switch to externally enable and disable inlet header pressure control. (Contact Input #3 Function: Casc Control Enable) The Cascade Input was inverted to allow the correct control action.
  • Page 32 When the plant-to-utility tie-line breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load set point up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load set point and is defaulted to 3%.

  • Page 33: Figure 3-3. Exhaust Pressure Control With Generator Power Limiting And Plant Import/Export Limiting

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators With this application the Auxiliary control is programmed to be used as a limiter, and be automatically enabled when both the Utility Tie and Generator breakers are closed. When paralleled to the utility, if inlet header pressure demand, and/or...
  • Page 34 In order to limit generator load, the 505 control must be able to sense generator load. As shown in Figure 3-3 generator load is being sensed with a Woodward Real Power Sensor and supplied to the 505’s KW droop input.
  • Page 35 Analog input #1. (Analog Input #1 Function: KW/Unit Load Input) Because the RPS’s KW readout is self powered, the 505 back cover was removed and JPR11 installed. Generator load (when paralleled to the utility) is controlled by the Speed PID and programmed by selecting the KW/Unit load input.
  • Page 36 +5 A CT current (Input #3 20 mA Value = +XXXX). Because the RPS’s KW readout is self powered, the 505 back cover was removed and JPR15 installed. The utility-tie Real Power Sensor’s CT inputs were wired to allow the RPS’s 4 mA value to represent full import power and the RPS’s 20 mA value to...
  • Page 37 When the plant to utility tie line/breaker is closed, and the unit generator breaker closes, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator. This minimum load level is based on the speed/load setpoint and is defaulted to 3%.

  • Page 38: Figure 3-4. Plant Import/Export Control With Drfd Servo Interface

    With this RPS 12 mA represents zero power flow. Because of this feature the RPS #8272-726 can not, be used with the 505 to sense generator load/power.
  • Page 39 505 Digital Governor for Single/Split-Range Actuators This application uses an EGCP-3 LS for synchronization only. Because the EGCP-3 LS interfaces to the 505 through an analog signal, a 505 analog input must be programmed. The 505’s Analog Input #6 is the only analog input directly compatible with the EGCP-3 LS, thus it is required that this input be programmed to receive the EGCP-3 LS’s Speed Bias signal.
  • Page 40 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Dither is a low frequency ac current modulated on to the 505’s dc actuator– drive current to reduce stiction in linear type actuators. Because the 505’s actuator output is connected to the DRFD, dither was not required or used with this application.
  • Page 41 With this application, turbine inlet header pressure control is performed within the 505 through the Cascade PID controller. This is an ideal controller for this type of function because it can be enabled and disabled as desired by a system operator.

  • Page 42: Figure 3-5. Inlet Pressure Control With Isochronous Loadsharing Control In Island Mode

    When the unit is paralleled to the utility, the EGCP-3 LS is disabled and the 505’s internal load setpoint or Cascade PID (plant import/export power) is used to control/set unit load.
  • Page 43 EGCP-3 LS. This synchronizing function/ input can be enabled, through a contact input, function key, Modbus command, or the 505 service panel. As shown in Figure 3-5 a panel mounted (DPST) switch is used with this application to select automatic synchronization in both the EGCP-3 LS and 505.
  • Page 44 With this configuration plant frequency will be the average frequency of all units. The 505, has a feature that resets its frequency setpoint to the ‘RATED SPEED SETPOINT’ setting upon the utility tie breaker opening, thus assuring that all units will be at synchronous speed.

  • Page 45: Figure 3-6. Import/Export Control Or Exhaust Pressure Control With Isoch Load Sharing In Island Mode

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Example 6–Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode Figure 3-6. Import/Export Control or Exhaust Pressure Control with Isoch Load Sharing in Island Mode This application utilizes multiple turbine generators, and requires that all units have the capability to control different plant parameters depending on the status and health of each unit.
  • Page 46 Process Steam control (turbine exhaust pressure), and Loadsharing (used for plant import/export control or unit loadsharing). When a unit is switched to a Manual load control mode, its 505’s internal load setpoint determines unit load. This allows an operator to manually load or unload a unit to a set level if desired.
  • Page 47 505 service panel. The following list of notes are provided as a reference for application programmers to follow when programming the 505 to achieve any control and limiting actions shown in Figure 3-6. 505 Configuration Notes for Example 6 OPERATING PARAM: This is a Generator application.
  • Page 48 With this configuration the mode of operation the system operates in is dependent on SW2’s position. When SW2 is not selecting the Loadsharing mode, and the generator breaker is closed, unit load is set by the 505’s internal Speed/load setpoint, or the Cascade PID if enabled. Upon the generator breaker closing, the 505 steps the speed/load setpoint up to a minimum load level to reduce the chance of reverse powering or motoring the generator.
  • Page 49 Example 7–Induction Generator Applications When the 505 is configured for induction generator applications, typically there are only two differences in the programming of the 505 verses programming for synchronous generator applications. The induction generator’s slip frequency must be taken into account. This is achieved by compensating for the slip frequency with the 505’s maximum Speed...

  • Page 50: Chapter 4. Operator Interface

    Chapter 4. Operator Interface Introduction Interface to the control may be performed through the 505’s service panel (located on the front of the control), remote switch contacts, analog inputs, meter readouts, relays, or a Modbus communications line to an operator interface device.

  • Page 51: Service Panel Modes And User Levels

    505 Digital Governor for Single/Split-Range Actuators Service Panel Modes and User Levels The 505 Service Panel operates in several modes and access user levels, each of which has a different purpose. The modes are: OPERATION, CALIBRATION, and CONFIGURATION. In order to enter and exit a particular mode, the user must be logged in with an appropriate user level.
  • Page 52 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Adjusting Values To adjust a value you first navigate the In-Focus highlighter to the correct value – then use the green Adjust Key to raise or lower the value. The ADJUST arrows will change a selected Service parameter by 1%. Using the ADJUST arrows in combination with the SHIFT key will change the service parameter by 10%.

  • Page 53: Chapter 5. Service Menu Procedures

    Service Menu Procedures Overview The service menu of the 505 control has the same easy to follow format as the program/configure mode. The service menus can be used to customize the control to be more application specific. The parameters that are tuned in the service menus may affect system performance, caution is advised.

  • Page 54: Figure 5-2. Authorized And Unauthorized Components

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 5-2. Authorized and Unauthorized Components The arrow keys (STEP LEFT, STEP RIGHT) allow you to move right or left across the tops of the function the Service mode columns. The STEP UP and STEP DOWN keys allow you to move up or down the columns.

  • Page 55: Figure 5-3 Service Menu

    The intent of the organization and arrangement of the pages is that page 1 contains the page that directly relate to the previous 505 Service header menus on the 2 line display. Page 2 contains features that are new with this product.
  • Page 56 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Service Menu list: Speed Control—monitor or change the program or default settings of; rate to min; setpoint slow rate; delay for the fast rate; setpoint fast rate; speed setpoint entered rate; underspeed setting; on-line and off-line derivative;...
  • Page 57 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Local/Remote—monitor or change the program or default settings of; remote ennobled; enable contacts; contacts enabled; enable Modbus 1; Modbus 1 enabled; enable Modbus 2; Modbus 2 enabled; Key Options—allow or disable controlled stop and dynamics adjustments;...

  • Page 58: Service Mode Parameters

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Service Mode Parameters Speed Control Settings RATE TO MIN ( RPM/S) dflt= xxx (0.01, 2000) Adjusts the rate the set point moves from zero to the minimum controlling speed when the unit is started. The minimum controlling speed will be either ‘idle’...
  • Page 59 Set to YES to permanently Hold the changes made to the Set Point Fast Rate, the Entered Rate, and Underspeed settings. To permanently save these changes into the 505, set to YES and select the ‘CLEAR’ key twice. Remote Speed Settings (only displayed if configured) Note: Available as the last page of the “Speed Control”...
  • Page 60 HOLD LIMITER CHANGES ? dflt= NO (Yes/No) Set to YES to Hold the changes made to the Entered Rate. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. MPU Override USE MPU OVERRIDE TIMER ?
  • Page 61 The following information is provided to display the information useful to the auto start sequence. It allows the operator to check all the times and rates that the 505 is using for the present start sequence. HOURS SINCE TRIP (HRS)
  • Page 62 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Pressure Compensation (only displayed if configured) The pressure compensation setting are used to bias the actuator 1 (V1) position based on inlet pressure. Pressure 1 dflt= *0.0 (0.0, 10000.0) Input point #1 of the pressure compensation curve, in engineering units.
  • Page 63 50 or 60 Hz. For example, if rated speed is 3600 rpm = 60 Hz, but the grid is actually running at 60.1 Hz, then this value can be tuned to 0.1 Hz so that the deadband in the 505 will be at 3606 rpm, the actual “speed” of the grid.
  • Page 64 NO (Yes/No) Set to YES to permanently hold the changes made to the Load Share Gain (%). To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Speed Droop (only if generator unit)
  • Page 65 Set to YES to permanently Hold the changes made to the Set Point Fast Rate, Entered Rate, and Rated Aux Set Point. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Remote Auxiliary Settings (only displayed if configured) Note: Available as the last page of the “Auxiliary Control”...
  • Page 66 Set to YES to permanently Hold the changes made to the Set Point Fast Rate, Entered Rate, and Rated AUX 2 Set Point. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Remote Auxiliary 2 Settings (only displayed if configured) Note: Available as the last page of the “Auxiliary 2 Control”...
  • Page 67 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum AUX 2 Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key.
  • Page 68 Entered Rate, Rated Setpt, Casc Not Matched Rate, Maximum Speed Setting and Minimum Speed Setting. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Remote Cascade Settings (only displayed if configured) Note: Available as the last page of the “Cascade Control” Service menu.
  • Page 69 Set to YES to permanently Hold the changes made to the Remote Not Matched Rate and the Maximum and Minimum Casc Settings. To permanently save these changes into the 505, set to YES and select the ‘Save Settings’ key. Communications (only displayed if configured)
  • Page 70 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 PORT 3 ENABLE WHEN LOCAL ? dflt= NO (Yes/No) If using Local/Remote only. If YES, allows commands from Modbus port 3 to be active even when LOCAL mode is selected. When NO, the Modbus commands from port 3 are disabled when in LOCAL.
  • Page 71 (status indication only) Shows the Ethernet IP address that is connected to this socket. IP address ‘127.0.0.1’ will be identified as the 505 front panel display, which will be used as “Local” for Local/Remote functionality. See volume 1 of the manual for details.
  • Page 72 This is configured by default as the Actuator 1 channel output. HP is the same functionality as “Actuator 1” in the older 2-line display non-extraction 505’s. When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 73 HP2 is the same functionality as “Actuator 2” in the older 2-line display non- extraction 505’s. HP2 can be used for dual inlet or split range valve applications. When this header appears in the display, press the down arrow key to view or change this block or press the left or right arrow key to select another block to change.
  • Page 74 Displays the actuator demand (%) after the linearization curve. Real Time Clock USE SNTP SYNCHRONIZATION dflt= NO (Yes/No) Select this option if using an SNTP Server for time synchronization with the 505 internal clock. This will affect alarm and event indication time stamping. Woodward...
  • Page 75 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Data Log DATA SAMPLE RATE dflt= 1000.0 (10, 1000) Set the number of milliseconds between each data point in the data log. FILE LENGTH dflt= 28800.0 (60, 1000000) Set the requested length of the data log in seconds. This is requested because the file length may be limited by memory and file size restrictions, for example, 4 MB.
  • Page 76 “Reset Alarm” soft key at the bottom of the screen if the appropriate security level is logged in. PEAK SPEED REACHED (status indication only) This indicates the maximum turbine speed detected by the 505. MAXIMUM ACCELERATION REACHED (status indication only) This indicates the maximum turbine acceleration detected by the 505.
  • Page 77 This is the Proportional gain setting for the Isolated Control PID. It can be adjusted by a user with the appropriate user level. The PID algorithm is the same as the other 505 control PID’s. See the PID tuning section of the manual for details on the PID parameters.
  • Page 78 If “Auto Login as Operator” is selected, this sets the Operator password. If the user level and password have not been changed, the default input will allow the 505 to login the Operator user level as described above. If the Operator password has been changed, then it must be entered here to authorize the 505 to automatically login to the Operator user level.
  • Page 79 Set the maximum length of time, in seconds, that Manual Valve Demand may be enabled. If Manual Valve Demand is enabled for this length of time then it will automatically be disabled and the 505 will return to Speed PID Control.

  • Page 80: Chapter 6. Understanding Pid Settings

    They correspond to the P (proportional), I (integral), and D (derivative) terms, and are displayed by the 505 as follows:  P = Proportional gain (%) ...

  • Page 81: Proportional Response

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Derivative, sometimes called “preact” or “rate”, is very difficult to draw an accurate analogy to, because the action takes place only when the process changes and is directly related to the speed at which the process changes.

  • Page 82: Figure 6-2. Open Loop Proportional And Integral Response

    If there is no error, then there is no Proportional effect. Integral Response Integral Gain as stated in the Woodward controls is repeats per minute (or Reset Rate). Therefore, a high amount of Integral gain (high number) would result in a large amount of Reset action.

  • Page 83: Proportional + Integral (Closed Loop)

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Integral response is provided to eliminate the offset that resulted from straight Proportional control. Figure 6-2 shows how the controller action is Proportional to the measurement change, but as we saw earlier, this results in offset. The Integral (or Reset) action is a function of both time and magnitude of the deviation.

  • Page 84: Derivative Response

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 In Closed Loop, however (as opposed to Open Loop), as the measurement decays toward the Setpoint the Proportional action is taking place Proportionally to the measurement change, and the Integral action is decaying proportionately to the magnitude and duration of the deviation until the measurement reaches the setpoint at which time the Integral action is zero.

  • Page 85: Proportional + Derivative (Closed Loop)

    Proportional action to reduce stabilization time in returning the process to the setpoint after an upset. Derivative will not remove offset. Woodward Derivative is split into two working domains, Input dominant and Feedback dominant. The allowed values for DR range from 0.01 to 100. The most common derivative is Feedback dominant, it is automatically selected with an Derivative Ratio (DR) from 1 to 100.

  • Page 86: Figure 6-5. Closed Loop Proportional And Derivative Action

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure 6-5. Closed Loop Proportional and Derivative Action Derivative (effects of settings) Figure 6-6. Derivative Setting Effects Woodward...

  • Page 87: Proportional + Integral + Derivative (Closed Loop)

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure 6-6 shows the effect of different Derivative settings. The curves are relative since it depends on what type of control is desired in order to properly adjust Derivative time. For example, if minimum cycling is desired (as is shown here) then Derivative is added to the 1/4 decay cycle provided by Proportional until more than one cycle is removed and of course the 1/4 decay is destroyed.

  • Page 88: Controller Field Tuning General

    The value of the Derivative Ratio (DR) term can range from 0.01 to 100. In order to simplify adjustment of the dynamics of the 505, adjusting the integral gain value sets both the I and D terms of the PID controller. The DR term establishes the degree of effect the integral gain value has on the “D”...

  • Page 89: Figure 6-8. Typical Response To Load Change

    1 second reduce the Integral gain term (proportional gain may need to be increased also). On an initial startup with the 505, all PID dynamic gain terms will require adjustment to match the respective PID’s response to that of its control loop.
  • Page 90 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 The following method can be used to achieve PID gain values that are close to optimum: 1. Increase Derivative Ratio (SDR) to 100 (Service Mode adjustment) 2. Reduce integral gain to 0.01 (Run Mode adjustment) 3.

  • Page 91: Chapter 7. Hardware/Operating System Faults

    GND terminal (11) with input wiring disconnected, replace the 505. The operation of a contact input to the 505 can be checked by verifying that the voltage from the contact input’s (+) terminal measures 24 Vdc with respect to the contact input GND, terminal (11), when the external contact is closed.

  • Page 92: Control Adjustments

    If an actuator hunts, or appears sticky, it may need dither (especially TM type). If the 505 control is not able to fully close or open the governor valves, check to make sure that the actuators are calibrated correctly, and valve linkage is correctly set.

  • Page 93: 505 Design Specifications

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix A. 505 Design Specifications Hardware Specifications Package Flush mount package Approximate physical size of 11” x 14” x 4” Environmental Category: Refer to Regulatory Compliance section of Volume 1 (some listings are dependent on part number) Built-In Graphical User Interface (GUI) 1.

  • Page 94: 505 Service Mode Worksheet

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Appendix B. 505 Service Mode Worksheet Governor Serial Number __________________ Application ____________________________ Date _______ For details on individual settings, refer to Chapter 4. SPEED CONTROL Rate to Min RPM/s Slow Rate Offline...
  • Page 95 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Use MPU Override Timer? Override Time MPU 1 Override On (status) MPU 2 Override On (status) IDLE/RATED RAMP (if configured) Hours Since Trip (status) Hot Reset Timer Idle/Rated Cold Rate RPM/s Idle/Rated Warm Rate...
  • Page 96 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 BREAKER LOGIC (if configured) Frequency Control Armed (status) Sync Window RPM Sync Window Rate RPM/s Tie Breaker Open Ramp Tie Open Rate RPM/s Generator Open Setpoint Zero Load Value (HP valve %)
  • Page 97 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Not Matched Rate units/s Remote Auxiliary Maximum Rate units/s Minimum Remote Auxiliary Setpoint units Maximum Remote Auxiliary Setpoint units Remote Deadband Value units Lag-Tau Value Hold Remote Auxiliary Changes AUXILIARY 2 CONTROL (if configured)
  • Page 98 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Not Matched Rate units/s Remote Cascade Maximum Rate units/s Minimum Remote Cascade Setpoint units Maximum Remote Cascade Setpoint units Remote Deadband Value units Remote Lag-Tau Value Hold Remote Cascade Changes COMMUNICATIONS Modbus Settings...
  • Page 99 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Socket 4 (status) Status (status) Level (status) Socket 5 (status) Status (status) Level (status) Socket 6 (status) Status (status) Level (status) Socket 7 (status) Status (status) Level (status) Socket 8 (status) Status...
  • Page 100 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Y-1 Value X-2 Value Y-2 Value X-3 Value Y-3 Value X-4 Value Y-4 Value X-5 Value Y-5 Value X-6 Value Y-6 Value X-7 Value Y-7 Value X-8 Value Y-8 Value X-9 Value...
  • Page 101 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators REAL TIME CLOCK Use SNTP Synchronization DATA LOG Data Sample Rate File Length OPERATION LOG Number of Turbine Starts Number of Hot Turbine Starts Total Trips Trips with Load > 25% Trips with Load > 75% Total Run Time Hours Run Time Hours with Load >...
  • Page 102 505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Maximum Minimum Initial Normal Rate Fast Rate Commands Remote Setpiont Remote Setpoint (status) Remote Rate units/s PID Dynamics P Term I Term DR Term SCREEN SETTINGS Screen Saver Delay Auto Login as Operator? Operator Password CUSTOM TREND ...
  • Page 103 Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Y Maximum units Y Minimum units Width Show Axis Signal 5 (Orange) Variable Y Maximum units Y Minimum units Width Show Axis VALUES FROM VARISTROKE II (HP VALVE) Varistroke II status information.

  • Page 104: Appendix C. Password Information

    Appendix C. Password Information General The 505 Series control system requires a password to be entered before access can be given to the OPERATOR, SERVICE, CONFIGURE, or ServiceUser modes. These passwords are intended to help prevent unauthorized or untrained personnel from accessing these modes and possibly making changes that could cause damage to the turbine or associated process.

  • Page 105: Appendix D. Servlink-To Opc Server (Sos) Tool

    SOS Communication Link The Woodward SOS Servlink OPC server ("SOS") provides an OPC interface for Woodward controls. It runs on a Windows PC that accesses data on controls using the Woodward proprietary Servlink protocol through an Ethernet connection. Woodward OPC client applications, such as Monitor GAP and Control Assistant connect to SOS by selecting a 'Servlink OPC server' connection.

  • Page 106: Connecting A Pc/Laptop To The Control

    The Woodward SOS tool is a sub-component of Control Assistant that handles all of the communications between 1 or many 505’s on a network and the PC. It can be run independently which is a useful way to clearly establish a connection prior to using the Control Assistant or other programs.

  • Page 107: Figure D-4. Sos - New Session Box

    505 Digital Governor for Single/Split-Range Actuators Under Session – scroll down and select New Session and a dialog box similar to the one below will appear. In the top entry box enter the IP address of the 505. Figure D-4. SOS – New Session box If you are connected to Ethernet Port 1 of the 505, enter the IP address of this port.

  • Page 108: Appendix E. Control Assistant-Software Interface Tool

    It provides a flexible window into the application software with multiple features for the user. The install for this program is included on the system documentation CD, the latest releases and updates are always available on the Woodward.com website. Features ...

  • Page 109: Figure E-2. Control Assistant Install Window

    Define the desired directory to save Control Assistant and press ‘Next’. It is preferable to use the default, as it will keep all Woodward Software in a common folder. If the program folder field is blank, type in “Woodward” and the install will create a program folder named Woodward.

  • Page 110: Using Control Assistant

    Control Assistant will NOT function properly until the PC is restarted. Using Control Assistant To launch Control Assistant: Under Start / All Programs / Woodward / Control Assistant 4 Click on Control Assistant 4 Use the Control Assistant HELP in the menu list to get familiar with all features of this product, or for additional information about using the features discussed in this chapter.

  • Page 111: Figure E-7. Dialog For Servlink Opc Connection

    (next sections). If multiple controls are available in SOS, they will all appear in the WinPanel window. Typical 505 users are not familiar with the GAP and therefore it is not expected to normally need to create new WinPanel views.

  • Page 112: Figure E-9. Control Assistant - Retrieve Tunable Dialog Box

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 What is valuable for a 505 user, is the ability to Open Winpanel View files that have been created by Woodward or by commissioning engineers. These files are identified as <filename>.ws files. This is a handy way to be able to gather system information, support tasks such as valve stroking, tuning or system checkout.

  • Page 113: Figure E-10. Control Assistant - Send Tunable Dialog Box

    If the 505 TRIPPED LED was ON (Trip is present) a confirmation box will appear that Lock IO was issued. If the 505 TRIPPED LED was OFF (no trips present) then the confirmation box will state it was not allowed...

  • Page 114: Figure E-11. Control Assistant - Speed Control Trend Script

    Manual 26839V2 Trending Control Parameters This can be done at any time and will not interfere with any 505 control functions. The first step is to follow the previous steps that were listed up to the point of having a WinPanel open and the correct control selected Use File/Open to open a previously saved trend script file (if you have one).

  • Page 115: Figure E-12. Control Assistant - Create Trend Script File

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Creating a Trend Script File Click on the New Trend icon if you want to create a new trend of parameters. A dialog box will appear and the user will be able to build a trend script file for view system parameters by expanding the explorer window on the left and ‘drag &...

  • Page 116: Appendix F. Appmanger Service Tool

    File Management with App. Manager AppManager is a Windows based remote access tool for Woodward controls. The 505 is loaded with a service that allows it to interface with AppManager. AppManager is used to manage the applications on the 505 and provide access to operating system information.

  • Page 117: Figure F-2. App Manager License Agreement Window

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure F-2. App Manager License Agreement Window To install App Manager, select “I accept the terms in the license agreement”. Once this has been selected, select Next to continue the installation. Figure F-3. App Manager Installation Choose the desired folder in the ‘Start Menu’...

  • Page 118: Figure F-5. Appmanager Window

    Next click on the “Control Name” of the 505 you want to connect to. The following dialog box will appear.

  • Page 119: Figure F-7. App Manager Connected To A Control

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators To connect to the control use the following Connect As: ServiceUser Password: ServiceUser@1 Click OK and the window should look something like this. Figure F-7. App Manager Connected to a Control Control Information Parameters From the main screen –...

  • Page 120: Figure F-9. Appmanager Control (Gap) Application Panel

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Switching Application Panel Views The application panel has 2 views - the control application panel has a white background while the GUI application window has a maroon background. To toggle between the panels use the swap button on the far right side (the second button down from the top).

  • Page 121: Figure F-11. Retrieving Files

    Figure F-11. Retrieving Files Transferring Files For most users there will not be any need to transfer new files to the 505, but if this need arises AppManager is the tool for doing this. To transfer files to the control, first be sure you are in the correct application window. For example to transfer a customize or updated GUI file –...
  • Page 122 AppManager is the tool that is used if a service pack needs to be installed to update the OS or the real-time process that executes the GUI application. Typically this will only be done by Woodward representatives or a service bulletin that directs the user through the process.

  • Page 123: Appendix G. Configuring Network Tcp/Ip Addresses

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix G. Configuring Network TCP/IP Addresses Figure G-1. Configuration/Communications Screen The ENET 1, ENET 2, and ENET 3 configuration refer to the physical Ethernet connections on the unit. ENET 4 is reserved and is not configurable through the front panel.
  • Page 124 IP Conflicts command, such as ‘ping’ to verify the availability of an IP prior to assigning it to a 505 control and placing the control on the network To set a new IP address to one of the Ethernet connections: ...

  • Page 125: Appendix H. Remoteview Tool

    Appendix H. RemoteView Tool The 505 Remote View tool is used to connect to the 505 controller via Ethernet and provide an interface that is identical to the front panel display. The Remote View tool connects to the control, downloads the GUI application, and launches it on a PC.

  • Page 126: Figure H-3. Installation Folder Window

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Select “Next” to continue. The Installation Folder window will open. A default installation folder will be shown. If a different installation folder is needed, click the “Browse…” button to select the new folder.

  • Page 127: Figure H-5. Installation Start Menu Shortcuts Window

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators The Start Menu shortcuts window will open. A default location in the Woodward program folder will be shown. If a different Start Menu location is needed, type the new location in the window or select one of the locations presented in the list.

  • Page 128: Figure H-7. Installation Complete Window

    Click “Finish” to close the window. The Remote View tool is now ready for use. Remote View Configuration To start the Remote View tool, go to the Start Menu and select 505 Remote View from the Woodward folder (or in the alternate folder specified at installation). The configuration window will open.

  • Page 129: Figure H-8. Entering An Ip Address To Be Added To The Control List

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-8. Entering an IP Address to be Added to the Control List When the address has been entered, click the “+” button to add the control to the list. When a control is selected in the Control list, the “Get app list” button becomes as available, as shown in the following figure.

  • Page 130: Figure H-10. Login Window With Fields For User Name And Password

    Application list After a successful login, the application list will show the applications that are loaded on the control. In almost all cases, the 505 control will have a single application loaded. After selecting an application, the “Launch” button will be available.

  • Page 131: Figure H-11. An Application Selected In The Application List

    The Remote View panel type has three choices for the appearance of the tool. The Default setting shows the tool as a replica of the actual 505 front panel. The Simple setting shows the tool as a replica of the actual 505 front panel, but with the right and bottom physical buttons hidden.

  • Page 132: Figure H-12. Default View Of The Tool

    505 Digital Governor for Single/Split-Range Actuators Manual 26839V2 Figure H-12. Default View of the Tool Figure H-13. Simple View of the Tool Woodward...

  • Page 133: Figure H-14. Full View Of The Tool

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Figure H-14. Full View of the Tool Predefined settings This dialog is used to manage settings for the Remote View tool. To save the current Remote View settings for the control list and the display properties, enter a name for the settings and the click “Save”.

  • Page 134: Figure H-16. A New Settings File Entered In The Predefined Settings List

    Using Remote View Before using the Remote View tool, complete the follow steps to connect to the 505 control. These steps are described in detail in the Remote View Configuration section. ...

  • Page 135: Figure H-17. Remote View Tool (Default Setting) After Opening From The Configuration Window

    PC. Use the Remote View tool in exactly the same way as the front panel, as described in Volume 1 of the 505 manual. The buttons on the Remote View screen can be selected with the PC mouse. The PC keyboard can be used to enter text.

  • Page 136: Appendix I. Using 505 Internal Simulation Mode

    505 prior to using the unit or wiring it to the turbine. This can be extremely valuable. It can be used to: ...

  • Page 137: Appendix J. Custom Tag Name Procedure

    Manual 26839V2 505 Digital Governor for Single/Split-Range Actuators Appendix J. Custom Tag Name Procedure Custom tags allow users to input stings for predefined parameters in any characters available in the Arial Unicode MS font family. This allows users to input tag names using a language other than English. The custom tags are input into the “custom_tags.ini”...
  • Page 138 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world. Complete address / phone / fax / email information for all locations is available on our website.

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